Multi-component coating compositions

ABSTRACT

This invention relates to aqueous &#34;multi-pack&#34; coating compositions, that is, those which comprise at least two discrete components (or &#34;packs&#34;) which are mixed prior to application. 
     Prior attempts to provide an aqueous multi-pack composition have failed to provide a suitable combination of the desirable characteristics of adequate &#34;pot-life&#34; (the time for which the mixed components remain workable) and early development of adequate mechanical properties. 
     The compositions of the present invention which provide such a combination consist of a number of components which together comprise a constituent having epoxide groups, a constituent comprising addition polymer in the form of an aqueous dispersion and a constituent capable of reacting with epoxide groups. In an especially preferred embodiment, the aqueous addition polymer dispersion is combined with at least one of the other constituets in the form of a multi-polymer particle dispersion. 
     The compositions are useful in the automotive refinish and heavy duty coatings areas.

This is a continuation of application Ser. No. 753,067 filed July 9, 1985, now U.S. Pat. No. 4,696,957, issued Sept. 29,1987.

This invention relates to coating compositions and more particularly to water-based multi-component coating compositions.

Multi-component coating compositions wherein the compositions comprise at least two components which are blended prior to application are well known to the art and have been used extensively for many years. They are especially useful in areas where it is impracticable to apply more than slight heating to a coated substrate in order to cure the coating. A typical example of such an area is the motor vehicle refinish industry. A further advantage of multicomponent systems is that it is easier to obtain optimum film properties. A single component thermosetting system must be both stable in a container, often for a long period, and able to react on application to form a cross-linked film; the simultaneous satisfying of these two conditions places constraints on the type of film-forming material which can be used.

Multi-component systems are not so constrained and the components can be formulated to give the best film properties; in addition careful formulation has ensured that such systems have an adequate "pot-life" (the time for which the mixed components remain workable). Thus, many heavy-duty systems which are required to have optimum performance under harsh conditions are multi-component systems. Well-known examples of multi-component systems are the epoxy/amine and urethane (isocyanate-cured) systems, both of which offer outstanding properties and which are extensively described in the literature.

Multi-component coating compositions have hitherto generally been organic solvent-based, but the constantly increasing cost of such solvents plus the desirability of reducing atmospheric pollution and health hazards has led to considerable interest in the possibility of water-based multi-component coating compositions. One example of such a coating composition comprises an aqueous epoxy resin and an aqueous amine hardener. However, it is often important in practice not only that coating compositions should have good pot life and good ultimate properties, but also that these good ultimate properties should be developed as quickly as possible. Known water-based multi-component coating compositions require unacceptably long times before they develop important properties such as acceptable hardness for service conditions, and this severely reduces their usefulness. The best of the known aqueous compositions comprise in addition to the typical ingredients of a two-component system a low molecular weight acrylic solution polymer. Compositions of this type have been marketed, but they are still clearly inferior to the known solvent-based compositions.

We have now found that it is possible to prepare multi-component coating compositions which combine the advantages of being water-based and of having good pot life with a speed of attainment of properties which can match and even exceed that of comparable solvent-based compositions. We therefore provide, according to the present invention, an aqueous coating composition comprising at least two discrete components which are mixed prior to the application of the composition to a substrate and which then react to form a continuous cross-linked coating film, the components comprising overall

(a) a constituent having a number average molecular weight of from 200-10,000 and comprising at least one epoxide group per molecule;

(b) an aqueous film-forming dispersion which comprises addition polymer; and

(c) a constituent capable of reaction with expoxide groups.

In this specification, constituent (a) shall hereinafter be referred to as the "epoxide constituent", constituent (b) as the "dispersion constituent" and constituent (c) as the "reactive constituent".

In the simplest form of our invention, the three constituents (a), (b) and (c) are kept in separate containers and mixed immediately prior to application. However, it is preferable for reasons of convenience of storage and use that only two containers be used. This may be achieved by blending (b) into either or both (a) or (c). In general, this embodiment of our invention works well so far as film properties are concerned, but many compositions of this type have been observed to have relatively short pot lives, which limits practical usefulness.

This limitation does not affect a preferred form of the invention wherein the individual particles of the dispersion constituent are blends of addition polymer and one of the other constituents. Such dispersions can readily be prepared by the techniques used in the preparation of multi-polymer particles. By "multi-polymer particles" we mean particles which comprise a blend of at least two polymers, at least one of which polymers (the "in situ polymer") is formed in the presence of at least one other polymer (the "pre-formed polymer"). Such particles and their preparation are described in, for example, British Pat. Nos. 1,417,713, 1,421,113 and 1,515,723, European patent application 0010424, U.S. Pat. Nos. 3,620,989, 4,373,054 and 4,413,073 and PCT Application No. WO84/00169.

Thus, the epoxide constituent or the reactive constituent may be the "pre-formed polymer" and the addition polymer the "in-situ polymer" in a dispersion constituent. In some cases (as will be further discussed hereinunder), the epoxide constituent or the reactive constituent or both may be polymeric and the disperse particles are actually "multi-polymer" in that all constituents are polymeric in nature. However, the method of preparation will work equally well with oligomeric and non-polymeric epoxide constituents and reactive constituents, and many of these give excellent results. Further references to "multi-polymer particles" and "pre-formed polymer" in this specification should thus be considered to encompass the use of such non-polymeric constituents

As stated in the preceding paragraph, either or both of the constituents (a) and (b) may be incorporated into an aqueous dispersion of multi-polymer particles, but it is generally the epoxide constituent which is used as the pre-formed polymer. This is done for a number of reasons, including the fact that the epoxide constituent generally is not as water-soluble or dispersible as the reactive constituent. The multipolymer particle approach can result in a unique blend of properties which combines the best features of the epoxide constituent and the addition polymer.

The epoxide constituent may be selected from a wide range of materials known to the art which have at least one (and preferably about 2) epoxide groups per molecule and which comply with the abovementioned molecular weight limits. Materials at the top end of our molecular weight range are solids which have to be dissolved, and we prefer to work lower in the range where the materials are liquids or low melting point solids. We have found that, for our purposes, especially good materials are bisphenol A-epichlorhydrin epoxy resins of molecular weight of from about 350-1200. Suitable materials can be selected, for example, from the "Epikote" or "Epon" (registered trade marks) range produced by the Shell Chemical Co. Such epoxy resins are especially suitable for use with our preferred multi-polymer particle method.

It is permissible, of course, to utilise a blend of different epoxy resins instead of a single epoxy resin. (In some cases, the commercially-available single epoxy resins are themselves really mixtures of different molecular weight compounds). In this case it is permissible for part of the epoxy resin blend to have a molecular weight outside the stated limits, provided that the average molecular weight of the blend lies within the limits.

Other epoxy group-containing materials may be utilised in our invention. It is possible, for example, to take a polymeric material with no epoxide groups and add such groups by reacting the material with a suitable epoxide group-containing material. The comments on individual and collective molecular weights in the immediately preceding paragraph also apply here.

When the epoxide constituent is to be an individual constituent, that is, it is not going to form part of an aqueous dispersion of multi-polymer particles, it must be capable of being dissolved or dispersed in water. This can be achieved by, for example, using an epoxide constituent which also comprises water soluble groups, or by using a suitable surfactant.

The dispersion constituent for use in our invention is an aqueous dispersion, the disperse particles of which may comprise homopolymer, copolymer or multi-polymer particles. In the case where multi-polymer particles are present, the "pre-formed polymer" is preferably the epoxide constituent or the reactive constituent it is permissible to have both constituents in different multi-polymer particle dispersions. It is also permissible for the multi-polymer particles to comprise, instead of or in addition to one or both of these two constituents, material which is different from these constituents. Such different material (which may be polymeric or non-polymeric) may be included, for example, to achieve a particular balance of properties.

The range of monomers suitable for preparation of the addition polymer for use in the dispersion constituent of this invention is large and depends on the desired final properties of the polymer. Examples of suitable ethylenically unsaturated monomers include styrene, the mixed isomers of methyl styrene known as "vinyl toluene", α-methyl styrene, the C₁ -C₁₈ alkyl acrylates and methacrylates and vinyl acetate. A small proportion of monomer having more than one ethylenically unsaturated double bond, e.g. divinyl benzene, can also be used, but an excessive degree of crosslinking should be avoided. It is also permissible to include a proportion of a monomer having a functional group. Such groups can enhance properties, for example, they can enhance adhesion to substrates or participate in the cross-linking reaction during film-formation. Examples of such monomers are glycidyl methacrylate and the lower (C₁ -C₄) hydroxyalkyl acrylates and methacrylates.

The aqueous dispersion, whether it comprise a single polymer or multi-polymer particles, may be prepared by any of the methods known to the art. The techniques of preparing a single copolymer dispersion are well known and a suitable copolymer can readily be prepared. Alternatively, a commercially available aqueous dispersion such as an acrylic latex may be used. Multi-polymer particle dispersions may be prepared by any of the methods known to the art. For the purposes of our invention, the multi-polymer particle dispersions may be stabilised by either conventional surfactants or the ethylenically unsaturated surfactants disclosed, for example, in European Published Application No. 0 002 252 and U.S. Pat. No. 4,413,073, or a combination of these.

When the coating compositions according to this invention are applied to a substrate, the addition polymer participates in the formation of the coating film. This participation may be assisted by the addition of any of the solvents, plasticisers or coalescing agents known to the art to improve film formation in addition polymer dispersions. However, in many cases, the other constituents of the composition can exert a plasticising effect on the addition polymer, thus rendering any such addition unnecessary.

The reactive constituent, which may be monomeric, oligomeric or polymeric, has reactive groups which will react with epoxide groups. One favoured group of compounds is that comprising polyamines and polyamides which are known to react readily with epoxide groups. The words "polyamine" and "polyamide" in this case refer to compounds having a plurality of amine and/or amide groups. They may be monomeric, for example, ethylene diamine, diethylene triamine and triethylene tetramine, or oligomeric or polymeric, for example, the "Wolfamid" (registered trade mark) series of polyamide resins available from Victor Wolf Ltd. As previously mentioned, the reactive constituent may be included in an aqueous dispersion of multi-polymer particles, but as it is generally more water-soluble or -dispersible than the epoxide constituent, we prefer to utilise the latter therein. In the case where an aqueous multi-polymer particle dispersion is not used and a two-component system is desired, the dispersion constituent may be blended with either or both of the other constituents, although we prefer to blend it solely with the epoxide constituent.

The proportions of the constituents which make up the components should be such that when the components are mixed prior to application, there should be present in the mixture from 0.2-1.5 equivalents of reactive group (of the reactive constituent) for every equivalent of epoxide group. Preferably there should be 0.5-0.9 equivalents of reactive group per equivalent of epoxide group. In addition, the addition polymer should comprise from 5%-80%, preferably 20%-60% by weight of the total solids of the film-forming components.

The compositions according to our invention may contain the normal known ingredients known to the art, such as pigments, extenders, suspending agents, coalescing agents, catalysts, thickeners and antifoams, in art-recognised quantities. The compositions are mixed prior to use and applied by any convenient means such as by brushing or spraying. They have the advantage over other water-borne systems that, while the chemical reaction between the two components and thus the ultimate film properties take some time to develop, the coating may be handled and processed long before this time. The compositions are thus useful, for example, as primer surfacers in the vehicle refinish industry or as heavy duty wall or floor finishes. In such application, they can have application and film properties equal to those of conventional solvent-based coatings combined with the economic and toxicological advantages of being waterbased.

The invention is further described in the following examples in which all parts are expressed by weight.

EXAMPLE 1

Preparation and comparative testing of a coating composition according to the invention wherein the epoxide constituent and the dispersion constituent each form part of a dispersion of multi-polymer particles. The composition was a two component system (or "two-pack" system to use the terminology of the paint industry) and these components shall hereinafter be referred to as "Pack A" and "Pack B". The ratio of reactive groups to epoxide groups in the total composition was 0.52:1.

Preparation of Pack A

The following ingredients were used:

    ______________________________________                                         The following ingredients were used:                                           barytes                21.0 parts                                              titanium dioxide       15.5 parts                                              china clay             22.8 parts                                              copper chromite         1.7 parts                                              polyamide.sup.1        34.0 parts                                              deionised water         5.0 parts                                              ______________________________________                                          .sup.1 a 20% solution of "Casamid" (trade mark) 362, ex Thomas Swan U.K. 

Pack A was prepared by loading the abovementioned ingredients to a ball mill and grinding for 16 hours to give a dispersion whose maximum particle size was less than 10 μm.

Preparation of Pack B

The following ingredients were used:

    ______________________________________                                               The following ingredients were used:                                     (a)   epoxy resin.sup.2     23.93 parts                                              methyl methacrylate   17.72 parts                                              butyl acrylate        5.28 parts                                               allyl acetoacetate    1.00 parts                                               stabiliser.sup.3      1.92 parts                                         (b)   t-butyl perbenzoate   0.64 parts                                         (c)   deionised water       4.83 parts                                         (d)   deionised water       38.70 parts                                        (e)   deionised water       4.70 parts                                               sodium erythorbate    0.28 parts                                               0.1% ferrous sulphate solution                                                                       1.00 parts                                         ______________________________________                                          .sup.2 "Dow" DER337 (ex Dow Chemicals)                                         .sup.3 "Teric" N40 (ex ICI Australia Ltd.)                               

The stabiliser was dissolved in the epoxy resin and monomers by mixing the materials (a) and warming to 60° C. (b) was added and the mixture (a)+(b) was emulsified into (c) by high speed mixing with a Cowles blade at 2000 rpm. This gave an emulsion with an average particle size of less than 1 μm and maximum size 2 μm. This emulsion was then diluted with (d) and polymerisation was initiated by the addition with stirring of (e). Stirring was then stopped and the polymerisation allowed to proceed to completion.

When the coating composition is used, Pack A and Pack B are mixed in the weight ratio of 100:66.5. The mixture had a pot life of over 1 day.

Testing of composition

The composition was sprayed on to steel panels and allowed to air dry. These were touch dry in 4 hours and could be sanded after 16 hours. After 24 hours, a portion of each panel was topcoated with a commercially-available two pack isocyanate-cured acrylic enamel. For the purpose of comparison, a similar set of steel panels was sprayed first with a commercially-available two pack isocyanate filler/primer surfacer and then with the abovementioned acrylic enamel. Both sets of panels were aged at 25° C. for 7 days and then subjected to the following series of tests;

(a) Gravelometer test. A panel was hung vertically in a gravelometer and bombarded with 400 g. of fresh gravel blown at the panel by an air blast at a pressure of 551.6 kPa (80 p.s.i.). The panel was then assessed on a scale of from 1 (complete removal of the paint film) to 10 (no visible damage).

(b) Adhesion test. This was carried out according to Ford Motor Co. Test Method BI 6-1, Part A, one of a series of test methods well known to the art. A panel was cross-scribed, adhesive tape was applied to the scribes and pulled away and the adhesion estimated from the amount of paint film remaining at the cross scribes.

(c) Humidity test. This test was carried out according to Ford Test Method BI 4-2 except that the temperature was lowered to 38° C. The panels were exposed to a high humidity atmosphere in a Cleveland humidity cabinet for 240 hours and the degree of blistering assessed by eye.

(d) Hardness test. This was carried out using a "Leitz" miniload hardness tester with a load of 25 g. The diamond was allowed to remain in contact with the film for 35 sec. and then removed. The length of the resulting indentation was then measured and this was converted into a knoop value.

The results of these tests were as follows:

    ______________________________________                                                   commercial  composition according                                              isocyanate primer                                                                          to the invention                                                   alone  topcoated                                                                               alone    topcoated                                   ______________________________________                                         (a) Gravelometer                                                                                9       9-10   8      9-10                                    (b) Adhesion    excellent                                                                               excellent                                                                             excellent                                                                             excellent                               (c) Humidity    good     good   good   good                                        performance                                                                (d) Hardness    10       14     7      14                                          (knoops)                                                                   ______________________________________                                    

It can be seen from the results that the performances of the commercial primer and the composition according to the invention are similar. The composition according to the invention has, however, the considerable advantage that it does not use potentially hazardous isocyanates.

EXAMPLE 2

Preparation of a coating composition according to the invention in which the dispersion constituent is a commercially-available copolymer. The composition was a two component system and these components shall hereinafter be referred to as "Pack A" and "Pack B". The ratio of reactive groups to epoxide groups in the total composition was 0.52:1.

Pack A in this case is identical to Pack A used in Example 1.

Preparation of Pack B

    ______________________________________                                         (a)     epoxy resin.sup.1                                                                             15.9 parts                                                      stabiliser.sup.2                                                                               0.8 parts                                              (b)     deionised water                                                                                3.2 parts                                              (c)     deionised water                                                                               13.5 parts                                              (d)     vinyl acetate/acrylic                                                                         30.0 parts                                                      copolymer latex.sup.3                                                  ______________________________________                                          .sup.1 "Dow" (trade mark) DER337 (ex Dow Chemicals), an epoxy resin of         epoxide equivalent weight 230-250.                                             .sup.2 "Teric" (trade mark) N40 (ex ICI Australia), a nonyl phenol             ethoxylate surfactant.                                                         .sup.3 "Acropol" (trade mark) S565 (ex A. C. Hatrick)                    

The ingredients (a) were warmed to 60° C. with stirring and held there until the stabiliser had melted and dissolved in the epoxy resin. (a) was then added to (b) under high speed mixing at 2000 r.p.m. with a Cowles blade. The resulting emulsion was diluted with (c) to give an emulsion of average particle size of about 1 μm. The mixture was allowed to cool and then added to (d) with slow stirring.

When the coating composition is used, Pack A and Pack B are mixed in the weight ratio of 100:63.

When tested in accordance with the methods of Example 1, the composition performed well, except that its humidity performance was slightly poorer than that of the composition of that example.

EXAMPLE 3

Preparation of a two-component coating composition according to the invention wherein the epoxide constituent and the dispersion constituent are combined in the form of a dispersion of multi-polymer particles. The ratio of reactive groups to epoxide groups in the total composition was 0.9:1.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         (a)    barytes (high grade 40 μm)                                                                    23.43 parts                                                  copper chromite   1.99 parts                                                   polyamide.sup.1   3.92 parts                                                   deionised water   14.55 parts                                                  flash rust inhibitor solution.sup.2                                                              0.40 parts                                                   antifoam.sup.3    0.10 parts                                            (b)    deionised water   7.00 parts                                                   antifoam.sup.3    0.50 parts                                            (c)    deionised water   5.26 parts                                            (d)    titanium dioxide  17.18 parts                                                  china clay (1 μm)                                                                             25.24 parts                                           (e)    thickener solution.sup.4                                                                         0.43 parts                                            ______________________________________                                          .sup.1 "Versamid" (trade mark) 125 (ex A. C. Hatrick)                          .sup.2 an aqueous solution of 9.3% sodium nitrite and 18.5% sodium             benzoate.                                                                      .sup.3 "Foamaster" (trade mark) NXZ (ex Diamond Shamrock)                      .sup.4 a 50% solution of a 9:1 mixture of "Collacral" (trade mark) PU85        and "Collacral" VL in a 60:40 mixture of propylene glycol and water      

Materials (a) were ball-milled for 18 hours to give a dispersion of maximum size 10 μm. Materials (b) were then added to the mill and milling continued for a further 15 minutes. The mill was then emptied and washed with material (c) and the washings added to (a)+(b). Materials (d) were added to half of (a)+(b)+(c) and this mixture subjected to high speed dispersion until a dispersion of maximum size 10 μm was obtained (this took about 30 minutes). The second half of (a)+(b)+(c) was then added and the mixture stirred for 5 minutes. Finally, material (e) was added with stirring.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)    methyl methacrylate                                                                              4.84 parts                                                   butyl methacrylate                                                                               14.73 parts                                                  hydroxypropyl methacrylate                                                                       4.89 parts                                                   epoxy resin.sup.1 2.45 parts                                                   stabiliser.sup.2  2.45 parts                                            (b)    epoxy resin       22.03 parts                                           (c)    coalescing agent.sup.3                                                                           4.63 parts                                                   t-butyl perbenzoate                                                                              0.65 parts                                            (d)    deionised water   4.63 parts                                            (e)    deionised water   33.56 parts                                           (f)    deionised water   2.73 parts                                                   sodium erythorbate                                                                               0.30 parts                                                   0.1% ferrous sulphate soln.                                                                      0.95 parts                                            (g)    thickener solution.sup.4                                                                         1.16 parts                                            ______________________________________                                          .sup.1 "Epikote" (trade mark) 828 (ex Shell Chemical Co.)                      .sup.2 "Teric" (trade mark) N40 (ex I.C.I. Australia Ltd.)                     .sup.3 "Texanol" (trade mark) (ex Eastman Chemical Co.)                        .sup.4 as material (e) in Pack A                                         

Materials (a) were heated to 60° C. with stirring, and material (b) was added and stirred until dissolved. This mixture plus materials (c) were added with high speed stirring (2000 r.p.m. with a Cowles blade) to materials (d). Stirring was maintained for 10 minutes, then material (e) was added and stirring continued for a further 5 minutes. The materials (f) were mixed and added to the mixture. Stirring was stopped at this point and the mixture allowed to exotherm. When the exotherm was complete and the mixture cooled to room temperature, it was filtered and material (g) added.

When the coating composition is used, Pack A and Pack B are mixed in a volume ratio of 1:1 (corresponding to a weight ratio of 171:97). The coating film produced therefrom performed well when subjected to the testing procedures of Example 1.

EXAMPLE 4

Preparation of a two component coating composition according to the invention wherein the epoxide constituent and the dispersion constituent are combined in the form of a dispersion of multi-polymer particles. The ratio of reactive groups to epoxide groups in the total composition was 0.4:1. The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         polyamide.sup.1    15.99 parts                                                 copper chromite     2.12 parts                                                 barytes (high grade 40 μm)                                                                     24.97 parts                                                 china clay (1 μm)                                                                              26.91 parts                                                 titanium dioxide   18.31 parts                                                 deionised water    11.70 parts                                                 ______________________________________                                          .sup.1 20% solution of "Casamid" (trade mark) 362 (ex Thomas Swan)       

The materials were loaded to a ball mill and milled for 16 hrs to give a dispersion of maximum particle size 10 μm.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)    epoxy resin.sup.1 21.97 parts                                                  methyl methacrylate                                                                              8.67 parts                                                   butyl acrylate    12.45 parts                                                  allyl acetoacetate                                                                               0.89 parts                                                   stabiliser.sup.2  1.77 parts                                            (b)    t-butyl perbenzoate                                                                              0.66 parts                                            (c)    deionised water   4.45 parts                                            (d)    deionised water   35.28 parts                                           (e)    deionised water   4.59 parts                                                   sodium erythorbate                                                                               0.26 parts                                                   0.10% ferrous sulphate soln.                                                                     0.92 parts                                            (f)    coalescing agent.sup.3                                                                           8.09 parts                                            ______________________________________                                          .sup.1 DER661 (ex Dow Chemicals)                                               .sup.2 "Teric" (trade mark) N40 (ex ICI Australia Ltd.)                        .sup.3 "Texanol" (trade mark) (ex Eastman Chemical Co.)                  

The materials (a) were stirred at 60° C. to dissolve the epoxy resin and stabiliser in the monomers. The mixture was then cooled to room temperature and material (b) was stirred in this mixture was then added to material (c) while (c) was being stirred at high speed with a Cowles blade at 2,000 r.p.m. (a)+(b)+(c) were then diluted with material (d) and stirred for 5 minutes. Premixed materials (e) were then added to initiate polymerisation. After the dispersion had exothermed and returned to room temperature, material (f) was added and stirred for 15 minutes.

When the coating composition is used Pack A and Pack B are combined in the weight ratio 100 to 98. The coating film produced therefrom exhibited good properties when tested according to the methods of Example 1.

EXAMPLE 5

Preparation of a two component coating composition according to the invention wherein the epoxide constituent and the dispersion constituent are combined in the form of a dispersion of multi-polymer particles. In this example, the dispersion constituent comprised 20% by weight of the film-forming solids.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         (a)     titanium dioxide 21.4 parts                                                    barytes (high grade 40 μm)                                                                   21.4 parts                                                    copper chromite   1.0 parts                                                    deionised water  14.9 parts                                                    polyamide.sup.1  18.5 parts                                            (b)     deionised water   6.7 parts                                            (c)     polyamide        16.1 parts                                            ______________________________________                                          .sup.1 a 20% aqueous dispersion of "Wolfamid" (trade mark) 3 (ex Victor        Wolf).                                                                   

The materials (a) were ground in a ball mill for 16 hours to give a dispersion whose maximum particle size was under 10 μm. The mill was drained and washed out with material (b), the washings being added to (a). Material (c) was then added to (a)+(b) and stirred at high speed for 15 minutes.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)    epoxy resin.sup.1 33.33 parts                                                  methyl methacrylate                                                                              6.79 parts                                                   butyl methacrylate                                                                               2.71 parts                                                   hydroxypropyl methacrylate                                                                       4.79 parts                                                   stabiliser.sup.2  2.40 parts                                            (b)    t-butyl perbenzoate                                                                              0.38 parts                                            (c)    deionised water   5.65 parts                                            (d)    deionised water   38.07 parts                                           (e)    sodium erythorbate                                                                               0.17 parts                                                   0.1% ferrous sulphate soln.                                                                       1.0 parts                                                   deionised water   4.71 parts                                            ______________________________________                                          .sup.1 DER337 (ex Dow Chemicals)                                               .sup.2 "Teric" N40 (ex ICI Australia Ltd.)                               

The materials (a) were mixed and heated to 60° C. to dissolve the epoxy resin and stabiliser. The mixture was then cooled to room temperature and material (b) was added. (a)+(b) were then added to material (c) while stirring at 2000 rpm with a Cowles blade. After stirring for 10 minutes, material (d) was added and stirring continued for a further 5 minutes. Premixed materials (e) were added and stirring was stopped. After the exotherm has finished, the mixture was cooled to room temperature and filtered.

The coating composition was used as a mixture of Pack A and Pack B in the weight ratio of 100 to 32.3. The coating film produced therefrom exhibited excellent properties when tested according to the methods of Example 1.

EXAMPLE 6

Preparation of a two component coating composition according to the invention wherein the dispersion constituent is a commercially-available copolymer. In this example, the dispersion constituent comprised 70% by weight of the film-forming solids.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         barytes (high grade 40 um)                                                                           21.43 parts                                              titanium dioxide      15.82 parts                                              china clay (1 um)     23.27 parts                                              copper chromite        1.74 parts                                              polyamide.sup.1       17.86 parts                                              deionised water       19.88 parts                                              ______________________________________                                          .sup.1 20% aqueous solution of "Casamid" (trade mark) 362 ex Thomas Swan.

The materials were loaded to a ball mill and ground for 16 hours to give a dispersion whose maximum particle size is 10 μm.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)     epoxy resin.sup.1                                                                             12.38 parts                                                     stabiliser.sup.2                                                                               0.62 parts                                             (b)     deionised water                                                                                2.49 parts                                             (c)     deionised water                                                                               10.51 parts                                             (d)     vinyl acetate/acrylic                                                                         74.00 parts                                                     copolymer latex.sup.3                                                  ______________________________________                                          .sup.1 DER 337 (ex Dow Chemicals)                                              .sup.2 "Teric" N40 (ex ICI Australia Ltd.)                                     .sup.3 "Acropol" S565 (ex A. C. Hatrick)                                 

The materials (a) were mixed and warmed to 60° C. to dissolve the stabiliser. They were then added without cooling to material (b) while the latter was being stirred at 2000 r.p.m with a Cowles blade. The resulting emulsion was diluted with material (c) and allowed to cool. It was then added to material (d) with stirring.

When the coating composition was used, Pack A and Pack B were mixed in the weight ratio of 100 to 70.5. The coating film produced therefrom exhibited good properties when tested according to the method of Example 1.

EXAMPLE 7

Preparation of a two component coating composition in which the reactive constituent is a modified amine.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         barytes (high grade 40 um)                                                                        19.85 parts                                                 copper chromite     1.71 parts                                                 titanium dioxide   14.56 parts                                                 china clay (1 um)  21.42 parts                                                 amine.sup.1         5.28 parts                                                 deionised water    37.18 parts                                                 ______________________________________                                          .sup.1 A 50% solution of D.E.H.52 (diethylene triamine modified with           liquid epoxy resin) (ex Dow Chemicals)                                   

The materials were loaded to a ball mill and ground for 16 hours to give a dispersion whose maximum particle size was 10 μm.

Pack B

This was identical to the Pack B of Example 2 except that 3.5% by weight of "Texanol" coalescing agent was added with stirring to the polymerised dispersion. Stirring was continued for 15 minutes.

When the coating composition was used, Pack A and Pack B were mixed in the weight ratio of 100 to 75.9. The coating film produced therefrom exhibited good properties when tested according to the methods of Example 1.

EXAMPLE 8

Preparation of a two component coating composition which utilises a high molecular weight epoxy resin. This epoxy resin forms part of a dispersion of multi-polymer particles.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

Pack A

Identical to Pack A of Example 4.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)    epoxy resin.sup.1                                                                               23.80 parts                                                   butyl acrylate   22.84 parts                                                   allyl acetoacetate                                                                              0.96 parts                                                    stabiliser.sup.2 1.92 parts                                             (b)    t-butyl perbenzoate                                                                             0.64 parts                                             (c)    deionised water  4.80 parts                                             (d)    deionised water  35.76 parts                                            (e)    deionised water  8.00 parts                                                    sodium erythorbate                                                                              0.28 parts                                                    0.1% ferrous sulphate soln.                                                                     1.00 parts                                             ______________________________________                                          .sup.1 "Epikote" 1004 (ex Shell Chemical Co.)                                  .sup.2 "Teric" N40 (ex ICI Australia Ltd.)                               

The materials (a) were mixed and heated with stirring to 60° C. to dissolve the epoxy resin. The mixture was then cooled and material (b) was added. (a)+(b) were then added to material (c) with stirring at 2000 rpm with a Cowles blade. After stirring for 10 minutes, the mixture was diluted with material (d) and stirring continued for a further 5 minutes. The premixed materials (e) were then added and the mixture allowed to exotherm. When the resulting dispersion was at ambient temperature, 6.5% by weight of "Texanol" coalescing agent was added and stirred in gently for 15 minutes.

When the coating composition was used, Pack A and Pack B were combined in the weight ratio of 100 to 96. The coating film produced therefrom exhibited good properties when tested according to the methods of Example 1.

EXAMPLE 9

Preparation of a two component coating composition which utilises a polyglycol epoxy resin and a catalyst. The epoxy resin forms part of a dispersion of multi-polymer particles.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         barytes (high grade 40 um)                                                                        21.85 parts                                                 titanium dioxide   16.03 parts                                                 china clay (1 um)  23.56 parts                                                 copper chromite     1.85 parts                                                 polyamide.sup.1    27.18 parts                                                 deionised water     8.76 parts                                                 catalyst.sup.2      0.77 parts                                                 ______________________________________                                          .sup.1 20% solution of "Casamid" 362 (ex Thomas Swan)                          .sup.2 DMP 30 (2,4,6tri(dimethylamino)phenol) (ex Rohm and Haas Co.)     

Pack A was prepared in the same way as Pack A of Example 1.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)    epoxy resin.sup.1 15.18 parts                                                  epoxy resin.sup.2 6.48 parts                                                   methyl methacrylate                                                                              15.40 parts                                                  butyl acrylate    1.97 parts                                                   hydroxypropyl methacrylate                                                                       4.33 parts                                                   stabiliser.sup.3  2.18 parts                                            (b)    t-butyl perbenzoate                                                                              0.58 parts                                            (c)    deionised water   4.41 parts                                            (d)    deionised water   35.05 parts                                           (e)    deionised water   4.30 parts                                                   sodium erythorbate                                                                               0.25 parts                                                   0.1% ferrous sulphate soln.                                                                      0.91 parts                                            (f)    Coalescing agent.sup.4                                                                           8.96 parts                                            ______________________________________                                          .sup.1 DER337 (ex Dow chemicals)                                               .sup.2 DER732 polyglycol epoxy (ex Dow Chemicals)                              .sup.3 "Teric" N40 (ex ICI Australia Ltd.)                                     .sup.4 "Texanol" (ex Eastman Chemical Co.)                               

Pack B was prepared in the same way as was Pack B in Example 4.

When the coating composition was used, Pack A and Pack B were combined in the weight ratio of 100 to 55. The coating film produced therefrom exhibited good properties when tested according to the methods of Example 1.

EXAMPLE 10

Preparation of a two component coating composition according to the invention for use as a wall finish. The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Preparation of multi-polymer particle dispersion                               ______________________________________                                         (a)    epoxy resin.sup.1 9.51 parts                                            (b)    epoxy resin.sup.2 14.27 parts                                                  methyl methacrylate                                                                              11.59 parts                                                  butyl methacrylate                                                                               7.43 parts                                                   hydroxypropyl methacrylate                                                                       4.76 parts                                                   stabiliser.sup.3  2.47 parts                                            (c)    t-butyl perbenzoate                                                                              0.59 parts                                            (d)    deionised water   4.76 parts                                            (e)    deionised water   38.34 parts                                           (f)    deionised water   5.05 parts                                                   sodium erythorbate                                                                               0.30 parts                                                   0.1% ferrous sulphate soln.                                                                      0.93 parts                                            ______________________________________                                          .sup.1 DER662 (ex Dow Chemicals)                                               .sup.2 "Epikote" 828 (ex Shell Chemical Co.)                                   .sup.3 "Teric" N40 (ex ICI Australia Ltd.)                               

Materials (b) were mixed and stirred at 60° C., and material (a) was added, stirring being continued until the epoxy resin was dissolved. The mixture was cooled, material (c) was added and the mixture of (a)+(b)+(c) added to material (d) while this was being stirred at 2000 rpm with a Cowles blade. After stirring for 10 minutes, the mixture was diluted by adding material (e). Stirring was continued for a further 5 minutes, and premixed materials (f) were added and the mixture allowed to exotherm. When the mixture had cooled, it was filtered.

    ______________________________________                                         Pack A                                                                         ______________________________________                                         (a)    sodium hexametaphosphate                                                                          0.12 parts                                           (b)    27% ammonium hydroxide                                                                            0.12 parts                                                  water-dispersible soya lecithin                                                                   1.24 parts                                           (c)    titanium dioxide   41.68 parts                                          (d)    deionised water    9.95 parts                                           (e)    propylene glycol   2.52 parts                                           (f)    antifoam.sup.1     0.37 parts                                           (g)    thickener solution.sup.2                                                                          0.71 parts                                           (h)    multi-polymer particle disper-                                                                    42.55 parts                                                 sion (as previously prepared)                                                  deionised water    0.64 parts                                                  bactericide        0.10 parts                                           ______________________________________                                          .sup.1 "Foamaster" NXZ (ex Diamond Shamrock Corp.)                             .sup.2 a 50% solution of GR708 (ex Rohm and Haas Co.) in a 60/40 mixture       of propylene glycol and water.                                           

Material (a) was dissolved in material (d), then materials (b) were added and the mixture was stirred at high speed until all of the ingredients were incorporated (about 5 minutes). To this mixture half of material (c) was added, followed by half of material (e). When the pigment was incorporated, the remainder of both materials (c) and (e) was added and the mixture stirred at high speed until the dispersion had a maximum particle size of less than 1 μm (this took about 30 minutes). Material (f), and then material (g) were added; finally, material (h) was added and thoroughly incorporated with slow stirring, and the mixture was filtered.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)      polyamide.sup.1                                                                             9.96 parts                                                        deionised water                                                                            21.19 parts                                               (b)      deionised water                                                                            68.85 parts                                               ______________________________________                                          .sup.1 "Versamid" (trade mark) 125 (ex A. C. Hatrick)                    

The materials (a) were mixed under high speed stirring with a Cowles blade until the polyamide was well incorporated (about 10 minutes). The mixture was then diluted slowly with material (b).

When the coating composition was used, Pack A and Pack B were mixed in the ratio of 2 to 1 (by volume) or 100 to 33.9 (by weight). The coating composition could be applied to a wall by any conventional means to give a film which not only had excellent mechanical properties but also developed these properties very soon after application.

EXAMPLE 11

Preparation of a two component coating composition which uses a high molecular weight polyamide and a low molecular weight epoxy. The polyamide forms part of a dispersion of multi-polymer particles. The epoxy is emulsified in water.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         (a)      epoxy resin.sup.1                                                                          31.01 parts                                                        stabiliser.sup.2                                                                            1.63 parts                                               (b)      deionised water                                                                             6.22 parts                                               (c)      deionised water                                                                            61.14 parts                                               ______________________________________                                          .sup.1 DER 337 (ex Dow Chemical Co.)                                           .sup.2 "Teric" N40 (ex ICI Australia)                                    

The materials (a) were mixed and warmed to 60° C. to dissolve the stabiliser. They were then added without cooling to material (b) while stirring at 200 rpm with a Cowles blade. The resulting emulsion was diluted with material (c) and allowed to cool.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)    polyamide.sup.1   35.27 parts                                                  methyl methacrylate                                                                              6.24 parts                                                   butyl acrylate    3.96 parts                                                   hydroxypropyl methacrylate                                                                       2.60 parts                                                   stabiliser.sup.2  1.92 parts                                            (b)    t-butyl perbenzoate                                                                              0.32 parts                                            (c)    deionised water   5.21 parts                                            (d)    deionised water   34.94 parts                                           (e)    deionised water   8.01 parts                                                   sodium erythorbate                                                                               0.52 parts                                            ______________________________________                                          .sup.1 "Versamid 100" (Ex A. C. Hatrick)                                       .sup.2 "Teric" N40 (ex ICI Australia Ltd.)                               

The materials (a) were stirred together at 60° C. to dissolve the polyamide and the stabiliser in the monomers. The mixture was then cooled to room temperature and material (b) was stirred in; this mixture was then added to material (c) while (c) was being stirred at 2000 rpm with a Cowles blade. After stirring for 10 minutes, material (d) was added and stirring was continued for a further 5 minutes. Materials (e) were mixed and added to the mixture. Stirring was stopped and the mixture allowed to exotherm. After the exotherm had finished, the mixture was cooled to room temperature and filtered.

The coating composition was used as a mixture, Pack A and Pack B in the weight ratio of 28.9 to 71.1. Films of this composition cured overnight at 25° C. and exhibited good water resistance.

EXAMPLE 12

Preparation of a two component coating composition according to the invention which uses an acrylic polymer of high glass transition temperature (Tg). This acrylic polymer formed part of a dispersion of multi-polymer particles.

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

    ______________________________________                                         Pack A                                                                         ______________________________________                                         (a)    epoxy resin.sup.1  31.74 parts                                                 methyl methacrylate                                                                               13.61 parts                                                 stabiliser.sup.2   2.27 parts                                           (b)    t-butyl perbenzoate                                                                               0.37 parts                                           (c)    deionised water    4.29 parts                                           (d)    deionised water    39.73 parts                                          (e)    deionised water    2.11 parts                                                  sodium erythorbate 0.16 parts                                                  0.1% ferrous sulphate solution                                                                    0.95 parts                                           (f)    Coalescent.sup.3   4.77 parts                                           ______________________________________                                          .sup.1 "Epikote" 828 (ex Shell Chemical Co)                                    .sup.2 "Teric" N40 (ex ICI Australia)                                          .sup.3 "Texanol" (Trade Mark) (Eastman Chemical)                         

The materials (a) were mixed and heated to 60° C. The mixture was then cooled and material (b) was added. (a)+(b) was then added to material (c) with stirring at 2000 r.p.m. with a Cowles blade. After stirring for 10 minutes, the mixture was diluted with material (d) and stirring was continued for a further 5 minutes. The materials (e) were mixed and added and the mixture was allowed to exotherm. When the resulting dispersion was at ambient temperature, materials (f) were added and the mixture was stirred gently for 15 minutes.

    ______________________________________                                         Pack B                                                                         ______________________________________                                         (a)      Polyamide   10.00 parts                                               (d)      deionised water                                                                            90.00 parts                                               ______________________________________                                    

Material (a) was added to material (b) with stirring, stirring being continued until material (a) was thoroughly dispersed.

When the coating composition was used, packs A and B were combined in the weight ratio of 35 to 65.

The above composition gave hard opaque films after 24 hours, which films hardened further on baking for 1/2 hr at 60° C.

EXAMPLE 13

Preparation of a two component coating composition according to the invention in which the stabiliser for the multi-polymer particles is made up a reactive and non reactive type in a ratio of 1:4 parts:

The two components shall hereinafter be referred to as "Pack A" and "Pack B".

Pack A

Pack A in this case is identical to Pack A used in Example 3.

Pack B

As in Pack B in Example 3 except that the stabiliser in this case was made up of 1.96 parts "Teric" N40 and 0.49 parts of the stabilising compound described in Example 1 of U.S. Pat. No. 4,413,073. 

We claim:
 1. A method of forming an aqueous coating composition comprising polymerizing monoethylenically unsaturated monomers in an aqueous dispersion in the presence of a dispersed epoxy resin to form an aqueous dispersion copolymer, the copolymer of said monoethylenically unsaturated monomers having a glass transition temperature in the range of about -55° C. to about 105° C., and then mixing the aqueous dispersion of copolymer and epoxy resin formed by said polymerization with an amine-functional resin in an amount to supply a weight ratio of amino hydrogen atoms to oxirane group of from 0.2 to 1.5. 